CO2 Monitoring & CSRD Compliance: IIoT Retrofit for Duchêne.

BotCraft secures accurate CO2 footprint in production for Duchêne Industries using Any2x

TL:DR (Too long didn’t read):

Duchêne Industries required a CSRD-compliant IIoT architecture for 20 critical machines in a brownfield environment. The challenge: fragmented energy data combined with strict NIS2 security requirements. In partnership with the Open Industry 4.0 Alliance, we delivered a secure edge-to-data-layer architecture. Our Any2x Bot connects the legacy systems and pre-processes the data. The result: audit-ready AAS data as a foundation for CO2 reporting and future optimizations.

Initial situation

Duchêne Industries faced a multiple challenge:

• Regulation & market access: The CSRD turns the exact CO2 footprint per part into a key competitive factor. Estimates lead to inflated costs for CO2 certificates or exclusion from supplier portfolios.
• Brownfield obstacles: The machine park is heterogeneous and partly decades old. Central data infrastructure and measurement points for electricity, gas, or compressed air were completely missing.
• Mandatory compliance: Any networking had to comply with the strictest standards, including NIS2, CRA (Cyber Resilience Act), and IEC62443.

The objective was clearly defined:
Capture the energy consumption per workpiece for 20 critical machines at two sites and provide this data in a standardized Asset Administration Shell (AAS).

The architecture blueprint

In collaboration with the Open Industry 4.0 Alliance (together with ifm, endian, secunet und intersystems), we implemented a scalable edge solution.

Project scope: From raw data to audit-ready values

The architecture at Duchêne Industries was developed as a reference solution and directly validated. Our focus was on data refinement in four phases:

Our Any2x Edge-AI Bot played a key role here by providing the infrastructure and necessary data pre-processing.

Keyresults and businessimpact of the architecture

• CSRD compliance: Transition from vague estimates to exact, audit-ready CO2 data.
• Cost control: Avoiding unnecessary costs by eliminating over-compensation of CO2 certificates.
• Security guarantee: The setup complies with NIS2 and IEC62443.
• Interoperability: Provision of all data in the Asset Administration Shell (AAS)

Lessons Learned

Implementing such a complex brownfield project yields valuable insights:

• Retrofit needs both: Without the combination of physical sensors and flexible software (Any2x), legacy machines remain silent.
• Security by design: NIS2 is not an option for brownfield projects; it is the foundation.
• The power of the alliance: Close collaboration with partners like InterSystems and ifm significantly reduced time-to-market

Outlook: Agentic Shopfloor AI

This architecture, based on our BotBay infrastructure, is the starting point for AI-powered manufacturing. With a clean data foundation, Agentic AI can now be utilized for:

• Smart Scheduling (PPS): Order planning based on CO2 efficiency and energy availability.
• CAD/CAM Optimization: AI-assisted adjustment of machining strategies to reduce tool wear and energy consumption.
• Procurement & Quality: Automated analysis of alarms and quality deviations to optimize purchasing and scrap rates.